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Rotax 914 series, Maintenance Manual

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MAINTENANCE MANUAL

BRP-Powertrain

Effectivity: 914 Series
Edition 2 / Rev. 0

12-20-00

page 33

January 01/2010

11.4) Expansion tank, radiator cap

General note

See 

Fig. 15

.

To equalize pressure in the cooling system, an expansion tank is 
required. If the pressure in the system rises above 1.2 bar (17.4 psi) as 
the coolant warms up, the pressure relief valve (1) opens and the coolant 
can flow into the expansion tank via the line (5). When the coolant cools 
down, the return valve (2) opens and the coolant is sucked back.

NOTES:

On older engines a radiator cap with opening pressure of
0.9 bar (13.0 psi) can be installed. See SI-914-022 “Run-
ning Modification“, latest issue.

Radiator cap

Inspect the rubber seal (3), the pressure spring (4) and the two valves 
incorporated in the radiator cap for damage and leaks. If necessary, 
replace with a new original radiator cap with 1.2 bar (17.4 psi) (6) open-
ing pressure.

NOTES:

The radiator cap must be tightened fully on the expansion
tank.

Expansion tank

Inspect sealing surface (7) and tube connection (8) of the expansion tank. 
Carry out visual inspection of tank for damage and scuffing marks.

Graphic

Checking Expansion tank, radiator cap.

Part

Function

1

Pressure relief valve

2

Return valve

3

Rubber seal

4

5

6

7

1

3

2

8

3

Summary of Contents for 914 series

Page 1: ...MAINTENANCE MANUAL LINE MAINTENANCE FOR ROTAX ENGINE TYPE 914 SERIES part no 899608 ROTAX 914 UL 3 WITH OPTIONS Ref No MML 914 ...

Page 2: ...or written permission of BRP Powertrain GmbH Co KG be disclosed in whole or in part to third parties This legend shall be included on any reproduction of these data in whole or in part Copyright 2010 all rights reserved ROTAX is a trade mark of BRP Powertrain GmbH Co KG In the following document the short form of BRP Powertrain GmbH Co KG BRP Powertrain is used Other product names in this document...

Page 3: ...ucture of the Manual follows whenever it is applicable the struc ture of the ATA Air Transport Association standards The Maintenance Manual is subdivided into the following chapters Subject Chapter Introduction Chapter INTRO List of effective pages Chapter LEP Table of amendments Chapter TOA General note Chapter 00 00 00 Airworthiness Limitations Chapter 04 00 00 Maintenance Chapter 05 00 00 Time ...

Page 4: ...d04520 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 INTRO page 2 January 01 2010 NOTES ...

Page 5: ...10 05 00 00 1 2 3 4 5 6 7 8 9 10 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 05 10 00 1 2 3 4 5 6 7 8 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 05 20 00 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01...

Page 6: ...age date 12 20 00 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01...

Page 7: ...66 67 68 69 70 71 72 73 74 75 76 Rear page 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 chapter page date ...

Page 8: ...d04856 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 1 LEP page 4 July 01 2010 NOTES ...

Page 9: ...IFIC APPROVAL OF THE EASA no chapter page date of change remark for approval date of ap proval from authorities date of issue signature 0 0 0 0 0 0 0 0 0 0 0 INTRO LEP TOA 00 00 00 05 00 00 05 10 00 05 20 00 05 50 00 12 00 00 12 10 00 12 20 00 all all all all all all all all all all all 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01 01 2010 01...

Page 10: ...d04522 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 TOA page 2 January 01 2010 NOTES ...

Page 11: ...ies includes all engines such as the 914 F and 914 UL Table of contents This chapter of the Maintenance Manual contains general and safety information concerning the operation of the aircraft engine Subject Page General note page 3 Abbreviations and terms used in this Manual Conversion table page 5 page 7 Safety Safety notice Instruction Maintenance concept Technical documentation Use for intended...

Page 12: ...d04523 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 00 00 00 page 2 January 01 2010 NOTES ...

Page 13: ...he aircraft manufac turer and or dealer For additional information on engines maintenance or parts you can also contact your nearest authorized ROTAX aircraft engine distributor ROTAX Distributors ROTAX Authorized Distributors for Aircraft Engines See latest Operators Manual or on the Internet at the official Homepage www rotax aircraft engines com Engine serial number When making inquiries or ord...

Page 14: ...d04523 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 00 00 00 page 4 January 01 2010 NOTES ...

Page 15: ...12 UL see OM Type designation 912 ULS see OM Type designation 912 ULSFR 912 ULS Version France 914 F see OM Type designation 914 UL see OM Type designation A Ampere A C Aircraft A F Across flat dimension ASB Alert Service Bulletin ACG Austro Control GmbH API American Petrol Institute ASTM American Society for Testing and Materials ATA Air Transport Association CAN CGSB Canadian General Standards B...

Page 16: ...part only Illustrated Parts Catalog nB as necessary only Illustrated Parts Catalog n a not available NDT non destructive testing Nm newton meter PSU power supply unit Rev Revision ROTAX is a trade mark of BRP Powertrain GmbH Co KG RON Research Octane Number RV Record of Revisions s v still valid only IPC S N Serial Number SB Service Bulletin SI Service Instruction SL Service Letter SMD Surface Mou...

Page 17: ...m3 1 dm3 0 26417 gal US 1 gal US 3 7854 dm3 Units of velocity 1 m s 3 6 km h 1 ft min 0 3048 m min 0 00508 m sec 1 m s 196 85 ft min 1 kt 1 852 km h 1 km h 0 53996 kn Units of mass 1 kg 2 2046 lb 1 lb 0 45359 kg spec fuel consumption 1 g kWh 0 001644 lb hph 1 lb hph 608 277 g kWh Density 1 g cm3 0 016018 lb ft3 1 lb ft3 62 43 g cm3 Units of torque 1 Nm 0 737 ft lb 8 848 in lb 1 ft lb 1 356 Nm 1 in...

Page 18: ...d04523 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 00 00 00 page 8 January 01 2010 NOTES ...

Page 19: ... without incurring obli gation to remove replace or discontinue any design specification fea ture or otherwise Measure Specifications are given in the SI metric system with the USA equivalent in parenthesis Symbols used This Manual uses the following symbols to emphasize particular informa tion This information is important and must be observed NOTES Indicates supplementary information which may b...

Page 20: ...e German version prevails Warning It is your responsibility to be completely familiar with the safety instructions including warnings and cautions described in this Manual These warnings and cautions advise of specific operating and servicing methods that if not observed can cause a serious engine malfunction or cause the engine to lose power in flight which can result in loss of life injury or da...

Page 21: ...g locking tab self locking fasteners etc must be installed or replaced with new ones where specified If the efficiency of a locking device is impaired it must be replaced Torque wrench tightening Torque wrench tightening specifications must be strictly adhered to WARNUNG NOTICE If not specified otherwise the threads are not lubricat ed when fastened ...

Page 22: ...tandstill After engine standstill longer than 2 months observe without fail the instructions for engine out of use Protect fuel and carburetor system against contamination Returning When returning the engine or its components e g propeller gearbox to an authorized overhaul or repair company ensure that the necessary doc umentation log book maintenance records etc are enclosed WARNUNG NOTICE Spare ...

Page 23: ...Mainte nance Chapter 00 05 and 12 The scope of line maintenance consists of removal installation and adjustment of engine components including part wear All procedures in this Manual are to be considered line maintenance NOTES Where applicable you will be referred to the Heavy Main tenance Manual for work above and beyond line mainten nace Maintenance II Heavy Mainte nance separate Manual Maintena...

Page 24: ...umentation Installation Manual Operators Manual Maintenance Manual Line and Heavy Maintenance Overhaul Manual Illustrated Parts Catalog Alert Service Bulletin Service Bulletin Service Instruction Service Letter Status The status of the Manuals can be determined with the aid of the table of amendments The first column indicates the revision state This figure should be compared with the revision pro...

Page 25: ...ey may not represent in full detail or the exact shape of the parts which have the same or similar function Therefore deduction of dimensions or other details from illustrations is not permitted NOTES The Illustrations and Documents in this Manual are stored in a document data file graphic data file and are provided with a consecutive irrelevant number This number e g 00277 is of no significance f...

Page 26: ...safety or durability testing and conform to no aircraft standards These engines are for use in experimen tal uncertificated aircraft and vehicles only in which an engine failure will not compromise safety NOTES These engines are technically equivalent to certified en gines and have been manufactured by BRP Powertrain us ing the same quality assurance system Engine stop page The operator assumes al...

Page 27: ...re descriped in chapter 05 and are a required by the authority in order to ensure the Continued Airworthiness See chap 05 00 00 Continued Air worthiness Scheduled inspections of the engine including replacement and overhaul of defined components are required in order to ensure the Continued Air worthiness of ROTAX aircraft engines Approval THE AIRWORTHINESS LIMITATIONS SECTION IS APPROVED BY THE E...

Page 28: ...d04858 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 1 04 00 00 page 2 July 01 2010 NOTES EASA approved ...

Page 29: ...r normal working conditions Table of contents In this chapter the maintenance of engine ROTAX 914 Series is described The description is subdivided into sections and description of function of the various systems Some overlapping maintenance instruc tions are treated as generally valid information at the beginning of this section Subject Page Maintenance General note Authorized personnel Procedure...

Page 30: ...d04524 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 05 00 00 page 2 January 01 2010 NOTES ...

Page 31: ...the engine manufacturer Parts and acces sories We particularly emphasize that parts and accessories not supplied as genuine BRP Powertrain parts are not verified for suitability by BRP Pow ertrain and thus are not authorized for use Installation and or use of such products may possibly change or negatively influence the constructive characteristics of the engine For damages resulting from use of n...

Page 32: ...nce on any of the tasks outlined herein See chap 00 00 00 section 3 4 Requisite knowledge of the task as a result of Type specific training for the applicable ROTAX aircraft engine which is approved by the national aviation authority and or BRP Powertrain or Experience in performing the task and Formal instruction from a BRP Powertrain authorized training facility or On the job instruction by a BR...

Page 33: ...f these marks don t ruin them WARNUNG WARNING Non compliance can result in serious injuries or death When carrying out maintenance and service work re spect without fail the safety regulations WARNUNG WARNING Non compliance can result in serious injuries or death This precautionary measure serves to avoid any inju ries in case of an unintentional start of the engine Principally ensure the followin...

Page 34: ...espected damage may be the conse quence 1 4 Trouble shooting General notes In the Operators Manual possible problems are listed At the same time a brief description of the necessary remedial action is given See chapter 12 in the Operators Manual for engine type 914 Series WARNUNG NOTICE In order to avoid mechanical damages never loosen or tighten screws and nuts with pliers but only with the speci...

Page 35: ...regulations and specifications of the producer in cluding the expiry date and instruction No part no Description Application Qty 1 899785 LOCTITE 221 violet medium duty screw securing agent 10 ml 0 003 gal US 2 897651 LOCTITE 243 blue medium duty screw securing agent 10 ml 0 003 gal US 3 899788 LOCTITE 648 high strength screw securing agent 5 ml 0 001 gal US 4 899789 LOCTITE 603 green oil tolerant...

Page 36: ...eable neutrally colored multi pur pose grease water resistant and highly adher ent Useable for temperatures from 35 C to 120 C 31 F to 248 F and can be subject ed to mechanical loads 18 n a Preservation oil Requirements The preservation oil has excel lent penetrating capabilities and reaches even tiny gaps it s highly effective additives protect against corrosion of metal surfaces 19 n a Very fine...

Page 37: ...d with Clenvex 2000 It is a solvent cold cleaner free of halogen on the basis of selected fuel fractions with tensides and is biologically disposable Never use caustic or corrosive cleaning agents 22 n a MICRONORM abrasive This abrasive is suitable for local and gradual very fine treatment of steel parts with rust film propeller shaft The MICRONORM abrasive contains no noxious matter is approved b...

Page 38: ...as for which there are no separate maintenance and repair instructions Self locking Respect without fail all additional indications regarding securing and seal ing means and lubrication of fixation elements Adhere to specified tight ening torques Nut securing When using a self locking nut take care that the polyamide insert ring on nuts according to DIN 985 as well as the securing element on nuts ...

Page 39: ...void engine troubles by the use of preventive maintenance Table of contents This chapter of the Maintenance Manual contains general information regarding TBO and time limits on rubber components Subject Page Definition of terms Operating hours Time limit Life cycle General Overhaul TBO page 3 page 3 page 3 page 3 page 4 Time limit Time limit for rubber parts Time limit for the coolant Annual inspe...

Page 40: ...d04525 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 05 10 00 page 2 January 01 2010 NOTES ...

Page 41: ...e readings of the electronic hour meter The planned inspections to be performed at certain intervals are based on experience from long test runs and field observations They are intended as precautionary maintenance measures in order to ensure continued trouble free operation of the engine 1 2 Time limit Definition Time limits are predetermined time spans and intervals which are based either on cal...

Page 42: ...e conditions which comply with the manufacturer s and the aviation authority s recommendations for the certi fication of airworthiness Maintenance of operation The TBO values approved by the relevant authorities are based on perfor mance tests and empirical values which have been gathered through operation of the engine and are required for the acceptance and certifica tion of airworthiness TBO va...

Page 43: ... For an overhaul the engine must be removed from the aircraft be cleaned preserved and all openings to be closed to prevent entering of contaminants WARNUNG NOTICE A general overhaul is due after a defined period of op eration or after a specified calendar life since initial start of operation whichever comes first WARNUNG NOTICE After reaching this time limit the engine has to be shipped to an au...

Page 44: ... or 10 years whichever comes first 1 SB 914 027 1000 hr to 1200 hr i e 10 to 12 years whichever comes first 1 914 F from 4 420 314 up to and incl 4 420 908 1200 hr or 12 years whichever comes first 1 SB 914 039 1200 hr to 2000 hr i e 12 to 15 years whichever comes first 1 914 F from 4 420 909 2000 hr or 15 years whichever comes first 1 None 914 UL from 4 417 501 up to and incl 4 418 103 1000 hr or...

Page 45: ...ists and reports of operation of maintenance of findings and of oil analyses 3 The engine assembly as per supply volume Additionally all added on parts as in the supply volume such as carburetors filters fuel pump external generator sensors ignition unit electric starter oil tank 4 Indication of total engine operating hours TSN and where applicable engine operating hours since a previous overhoul ...

Page 46: ...not in the maintenance schedule of air craft manufacturer carburetor sockets diaphragm on both carburetors rubber hoses on compensating tube V belt 2 2 Time limit for the coolant General note Coolant must be replaced as per manufacturers instructions at the latest during overhaul or when the engine is replaced 2 3 Annual inspection General note A 100 hr inspection is to be carried out periodically...

Page 47: ... the maintenance and air worthiness of the engine the owner or user should only have the mainte nance work carried out by qualified engineers Documentation required It is the responsibility of the owner and or user to make sure that the air craft mechanic performing the work on the engine has access to the pre vious inspection protocols and any other required documents Table of contents This chapt...

Page 48: ...d04526 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 05 20 00 page 2 January 01 2010 NOTES ...

Page 49: ...eans that if a 100 hr check is actually carried out at 110 hr the next check will be due at 200 hr 10 hr and not at 210 hr 10 hr If maintenance is performed before the prescribed interval the next maintenance check is to be done at the same interval e g if first 100 hr check is done after 87 hours of operation the next 100 hr check must be carried out after 187 hours of operation Special hr check ...

Page 50: ...d04526 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 05 20 00 page 4 January 01 2010 NOTES ...

Page 51: ...operation part inspection possible danger Engine cowling for discoloring and warping Danger of overheating Exhaust fixation re tighten the exhaust fixation on the cylinder head after the first 2 hr of operation Leakage Fuel filter of fuel filter on airframe side for foreign bodies sealing material and loose fragmented material Engine to misfire Power loss Engine running too lean Engine malfunction...

Page 52: ...d04526 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 05 20 00 page 6 January 01 2010 NOTES ...

Page 53: ...ting surface condition cleanliness deformation cracks in welding seams or due to material fatigue or stress corrosion and other visually evident damage Fuel Air and Oil lines Cracks dents kinks required flexibility collapsed lines hoses abrasion cleanliness secure seating and other visually evident damage Wiring General cleanliness loose corroded or broken terminals chafed broken or worn insulatio...

Page 54: ...d04526 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 05 20 00 page 8 January 01 2010 NOTES ...

Page 55: ...heck e g 100 hr check must be noted on the top of each page of the maintenance check list All the maintenance work carried out must be initialled in the signa ture area by the aircraft mechanic performing the task Maintenance records After maintenance the completed check lists must be entered in the maintenance records The maintenance must be confirmed in the log book Discrepancies re medial actio...

Page 56: ...d04526 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 05 20 00 page 10 January 01 2010 NOTES ...

Page 57: ...nance Schedule Identification AIRCRAFT Registration number Aircraft make Aircraft model and S N Time since new Propeller brand Propeller model and S N ENGINE Engine type Engine S N TSN time since new TSO time since overhaul Used operating fluids coolant mixture ratio fuel oil AIRCRAFT OPERATOR Name Contact Address Telephone Fax E mail ...

Page 58: ...ev 0 05 20 00 page 12 January 01 2010 MAINTENANCE FACILITY Maintenance workshop Address Telephone Fax E mail Certificate This check is applicable circle on 25 hr 50 hr 100 hr 200 hr 600 hr Next check due at __________________________________hr TS________ engine hr Identification ...

Page 59: ...s for obstruction cracks wear and good condition Take note of changes caused by temperature influ ence recommended 50 hr X 12 20 00 sec 3 Visual inspection of the temperature sensor and the oil pressure sensor Inspect for tight fit and good con dition X Inspect all coolant hoses for damage including leak age hardening from heat porosity loose connec tions and secure attachment Verify routing is fr...

Page 60: ... 1 Inspect the exhaust system for crack formation and uncharacteristic gunpowder burns leaks X 2 Magnetic plug Check the magnetic plug at every oil change X 12 20 00 sec 14 3 Compression check Check the compression by the differential pressure method Test pressure________hPa psi every 200 hr 12 20 00 sec 5 4 Checking the engine suspension Inspect engine suspension and fasteners for secure fit incl...

Page 61: ...ation Mechanical or pneumatic synchronization X 12 20 00 sec 12 1 Inspect the float chamber assy for contamination and corrosion annual inspec tion 12 20 00 sec 12 4 9 Inspecting carburetor sockets and drip tray Inspect the carburetor sockets for damage and ab normalities checking for cracks wear and good con dition Take note of changes caused by temperature influ ence 1 See SB 914 019 latest edit...

Page 62: ...2 20 00 sec 17 1 Gearboxes with overload clutch Inspect overload clutch every 600 hr 1 05 50 00 sec 2 SB 914 020 Check the propeller gearbox with overload clutch every 1000 hr 12 20 00 sec 17 2 Check the propeller gearbox without overload clutch every 600 hr 12 20 00 sec 17 2 16 Oil change Remove old oil filter from engine and install new oil fil ter 50 hr 1 X 12 20 00 sec 13 3 13 4 Cut old oil fi...

Page 63: ... drop without ignition circuit A Off ___________rpm B Off ___________rpm A B difference ________rpm After engine test run re tighten the oil filter by hand only at cold engine Checks for leaks X 12 20 00 sec 8 General note All Service Instructions and Service Bulletins are complied with X Returning engine to service On the engine identified as per point 5 on the _____________________ the________hr...

Page 64: ...d04526 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 05 20 00 page 18 January 01 2010 NOTES ...

Page 65: ...h special check repair work an engine test run and a leakage check must be carried out WARNUNG NOTICE Observe without fail all the specified instructions Subject Page Engine check after propeller strike incidents Propeller gearbox with integrated overload clutch Propeller gearbox without integrated overload clutch Checking of the overload clutch Examination after engine failure Returning engine to...

Page 66: ...d04527 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 05 50 00 page 2 January 01 2010 NOTES ...

Page 67: ...ul the whole engine in accordance with the BRP Powertrain in structions for continued airworthiness Inspect all systems for correct functioning 2 Inspect add on components 3 Observe the directives of the aircraft manufacturer 4 Remove the gearbox and roller bearing of the propeller shaft 5 The whole gearbox must be inspected repaired or overhauled in accor dance with the BRP Powertrain instruction...

Page 68: ...bserve the directives of the aircraft manufacturer 4 Remove the gearbox and roller bearing of the propeller shaft 5 The whole gearbox must be inspected repaired or overhauled in accordance with the BRP Powertrain instructions for continued airworthiness but not limited too Carry out detailed inspection of all gearbox components NDT for cracks on gearbox housing propeller shaft and gear set Inspect...

Page 69: ...clutch drying out resulting in a higher torque Fig 1 08054 Step Procedure 1 Remove the propeller as per manufacturers instruction 2 Lock the crankshaft See chap 12 20 00 section 7 3 Danger of damage to the engine suspension Depending on the engine installation e g in the case of extremely lightweight engine suspension the gearbox must be removed and the test carried out on a suitable mounting atta...

Page 70: ...ver arm L used at the normal distance from it in m N x m Nm Obtained value The value determined must be between 600 and 800 Nm 442 and 590 ft lb If the value is greater or smaller than the limit value the overload clutch must be inspected repaired or overhauled in accordance with the BRP Powertrain instructions for continued airworthiness WARNUNG NOTICE Do not exceed 800 Nm 590 ft lb otherwise gea...

Page 71: ...buretor icing Ignition system shorting cable electronic module charging coil Spark plug malfunction grounding defect wrong spark plug connection Rough running engine part possible cause Ignition wiring assignment fault Carburetor fuel supply contamination in float chamber or float needle valve float chamber venting false air intake due to defective carburetor flange incorrect synchronization of th...

Page 72: ...der head temperature above normal operating limits see Operators Manual is a clear signal for a failure in the cooling system Camshaft bearings Conrod bearings rather consequential damage wear low oil pressure The entire assembly must be dismantled inspected and re paired Unintended engine stoppage by seizing part possible cause NOTICE Cylinder head temperature too high part possible cause Cooling...

Page 73: ...onents 3 2 Inspection in extreme climatic conditions General note Flying in deserts or areas with heavily contaminated or dusty air causes increased wear on all components For this reason shorter maintenance intervals are recommended Flying in areas with extreme climatic conditions or in extreme altitudes requires adjustment of the carburetor jetting and of the cooling system To do this it is nece...

Page 74: ... Step Procedure 1 Check that the push rods are straight Step Procedure 1 The whole engine must be inspected repaired or overhauled in accordance with the BRP Powertrain instructions for continued airworthiness 2 Check that the push rods are straight 3 Inspect the crankshaft for out of roundness See chap 72 00 00 of the Heavy Maintenance Manual 4 Inspect all systems for correct functioning 5 Detail...

Page 75: ...he relevant instructions 180 C 356 F 0 30 min Time Proceed as instructed in table 2 Proceed as instructed in table 1 Operating limit See Operators Manual 914 Series Max temperature exceeded up to 180 C 356 F briefly Step Procedure 1 The whole cooling system must be inspected repaired or overhauled in ac cordance with the BRP Powertrain instructions for continued airworthiness 2 Inspect all further...

Page 76: ...ust be inspected repaired or overhauled in ac cordance with the BRP Powertrain instructions for continued airworthiness 2 Inspect all further systems for correct functioning 3 Carry out detailed inspection of the affected engine components 4 Check compression by carrying out a differential pressure check 5 All cylinder heads and cylinders must be removed and subjected to a detailed check including...

Page 77: ... cylinder head temperature Please observe the relevant in structions 160 C 320 F 0 15 min Time Proceed as instructed in table 3 Proceed as instructed in table 4 Operating limit See Operators Manual 914 Series Excess temperature up to max 160 C 320 F max 15 min Step Procedure 1 The whole oil system must be inspected repaired or overhauled in accor dance with the BRP Powertrain instructions for cont...

Page 78: ... Step Procedure 1 The whole engine must be inspected repaired or overhauled in accordance with the BRP Powertrain instructions for continued airworthiness 2 Inspect all further systems for correct functioning 3 Carry out detailed inspection of the affected engine components 4 Inspect the whole oil system oil cooler oil lines must be inspected 5 Cut oil filter housing and inspect filter mat for for...

Page 79: ...88 Minimum oil pres sure on the ground Oil pressure below minimum oil pressure on the ground If noticed on ground immediately stop the engine and determine the cause Inspect the complete lubrication system trace cause and rectify See SI 914 007 latest issue WARNUNG NOTICE If the oil pressure falls below the minimum value other limits are often exceeded e g the oil temperature Please observe the re...

Page 80: ...ankcase pressure See Installation Manual 914 Series latest is sue 6 If no cause for the low oil pressure is found after the above checks carry out an oil change 7 If after the previous checks and oil change the oil pressure is still too low re pair or overhaul the engine in accordance with the BRP Powertrain instruc tions for continued airworthiness 8 Inspect all systems for correct functioning 9 ...

Page 81: ...he plug screw Fig 5 02712 Oil specification not respected Step Procedure 1 Oil change 2 Remove the lowest positioned banjo screw 1 banjo bolt plug screw or screw socket and drain the remaining oil from the crankcase Screw in ban jo bolt or plug screw Tightening torque see Installation Manual 914 Series 3 Replace oil filter 4 Drain oil completely from oil cooler 5 Drain oil from oil tank 6 Refill o...

Page 82: ... Powertrain instructions for continued airworthiness 3 Carry out detailed inspection of the affected engine components 4 Oil change 5 Remove the lowest positioned banjo screw 1 banjo bolt plug screw or screw socket and drain the remaining oil from the crankcase Screw in banjo bolt or plug screw Tightening torque see Installation Manual 914 Series 6 Replace oil filter 7 Drain oil completely from oi...

Page 83: ...e 1 Mark position of the spark plugs e g cyl 1 top and remove all spark plugs 2 Inspect the spark plugs for damage formation of melt beads burn off At heavy melt beads or bad burn off inspect the piston dome and cylinder wall by periscope If parts are damaged the engine must be inspected repaired or overhauled in accordance with the BRP Powertrain instructions for con tinued airworthiness 3 Inspec...

Page 84: ...FF and system grounded Disconnect neg ative terminal of aircraft battery Engine runs sluggishly Step Procedure 1 Remove spark plug connector and remove 1 spark plug from each cylinder 2 Torque must be determined with a suitable jig To do this determine the maximum occurring torque on the propeller shaft necessary to move the whole crank drive The torque must be max 150 Nm 110 64 ft lb 3 Carry out ...

Page 85: ...ual inspection check the boost pressure control See chap 76 00 00 of the Heavy Maintenance Manual 3 Check oil consumption 4 Oil level check See chap 12 10 00 section 4 1 WARNUNG WARNING Danger of serious injury The engine must not be put into operation until the cause has been ascertained and the fault remedied WARNUNG NOTICE If the permissible operating limits are exceeded or val ues fall below t...

Page 86: ... ascertained and the fault remedied WARNUNG NOTICE If the permissible operating limits are exceeded or val ues fall below the minimum the corresponding checks must be also be carried out Periodic rise and fall in boost pressure and speed Step Procedure 1 Visual inspection of the engine in particular Turbocharger Air intake system 2 Check wiring See 12 20 00 section 16 1 NOTE If no mechanical damag...

Page 87: ...xceeded WARNUNG WARNING Danger of serious injury The engine must not be put into operation until the cause has been ascertained and the fault remedied WARNUNG NOTICE If values have fallen below or exceeded further operat ing limits the corresponding checks must be also be carried out Red boost lamp lights up continuously Limit exceeded for up to 1 min Step Procedure 1 Visual inspection of the engi...

Page 88: ...s detected during the visual in spection check the boost pressure control See chap 76 00 00 of the Heavy Maintenance Manual Red boost lamp lights is flashing Limit exceeded for up to 1 min Step Procedure 1 No immediate checks are necessary as long as no further operating limits have been exceeded WARNUNG NOTICE If values have fallen below or exceeded further operat ing limits the corresponding che...

Page 89: ...ne Checks The following checks must be carried out WARNUNG WARNING Danger of serious injury The engine must not be put into operation until the cause has been ascertained and the fault remedied WARNUNG NOTICE If the permissible operating limits have been exceeded or values have fallen below the minimum the corre sponding checks must be also be carried out WARNUNG NOTICE In this emergency program m...

Page 90: ...ascertained and the fault remedied WARNUNG NOTICE If the permissible operating limits have been exceeded or values have fallen below the minimum the corre sponding checks must be also be carried out Failure of the voltage supply for the turbo control unit TCU Step Procedure 1 Visual inspection of the engine in particular Electric system voltage supply 2 Check wiring See chap 12 20 00 section 16 1 ...

Page 91: ...r shall evaluate field information and report to the authority In case of any relevant occurrences that may involve malfunction of the engine the form on the next page should be filled out and sent to the responsible authorized ROTAX distributor NOTES The form is also available from the official ROTAX AIR CRAFT ENGINES Homepage in electronic version www rotax aircraft engines com Register Document...

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Page 93: ...n 4 3 2 6 ENGINE COMPONENT Assembly that includes part Engine Comp Name Manufacturer Model or Part No Serial Number Engine TSN Engine TSO Engine Condition 7 Date Sub 8 Comments Describe the malfunction or defect and the circumstances under which it occurred State probable cause and recommendations to prevent recurrence Optional Information Check a box below if this report is related to an aircraft...

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Page 95: ...nation of the maintenance check list See 05 20 00 NOTES For reasons of clarity only headlines and keywords are listed in the Maintenance Schedule Please refer to the following pages for further explanation if needed As far as possible the content has been arranged accord ing to system Table of contents This chapter of the Maintenance Manual contains the most common maintenance procedures Subject C...

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Page 97: ... always be in a horizontal position before checking the fill levels Table of contents This chapter covers the steps required to replenish all operating fluids on the engine and also provides an overview of the fill capacities Subject Page General note page 3 Fluid capacities page 5 Cooling system Coolant check replenish page 7 page 7 Lubrication system Oil level check replenish page 9 page 9 ...

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Page 99: ...ain Effectivity 914 Series Edition 2 Rev 0 12 10 00 page 3 January 01 2010 1 General Servicing points on the engine Fig 1 08578 Part Function 1 Expansion tank 2 Radiator cap 3 Oil filter 4 Oil tank 5 Oil tank cover 6 Oil dipstick 4 6 2 3 1 5 ...

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Page 101: ... and types should be avoided The use of additives may result in damage System Fill capacity Details about the operating fluids Fuel system Refer to the relevant specifica tions provided by the aircraft manufacturer Refer to the corresponding chapter in the Flight Manual Cooling system approx 1 5 l 0 4 US gal Refer to the corresponding chapter in the Installation Manual Oil system MIN mark correspo...

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Page 103: ...lowly Sudden opening of the cap could pro voke the escape of boiling coolant and result in scald ing Step Procedure 1 Open the radiator cap 1 on the expansion tank 2 2 Check the coolant level The coolant level must be filled up to the top see sketch 3 Inspect coolant with densimeter or glycol tester Strongly discolored or thick ened coolant must be replaced 4 Use only coolant as recommended in the...

Page 104: ...INTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 12 10 00 page 8 January 01 2010 Graphic Coolant check replenish Fig 2 08523 Part Function 1 Radiator cap 2 Expansion tank KOPLWWHO FRRODQW 1 2 ...

Page 105: ...s process is completed when air flows back to the oil tank This air flow can be perceived as a murmur gurgling when the oil tank cover 1 of the oil tank is removed 3 Pull out the oil dipstick 2 4 The oil level in the oil tank should be between the two marks max min on the oil dipstick but must never fall below the min mark See Service Bulletin SB 914 026 Introduction of a new oil dipstick latest i...

Page 106: ...level check Replenish Fig 3 08524 Step Procedure 1 Operate the engine until the temperatures have stabilized for a period of 5 min engine oil temperature between 50 to 70 C 122 160 F 2 Switch the engine OFF 3 Allow the engine to cool down 4 Check for leaks 5 Check the oil level and top up with oil as required Part Function 1 Oil tank cover 2 Oil dipstick 1 2 8 7 PD PLQ 1 2 ...

Page 107: ... engine suspension Corrosion page 9 page 11 page 11 Leakage check page 13 Checking the compression Checking the compression for fault tracing page 15 page 17 Checking the V belt tension page 19 Locking the crankshaft page 21 Checking the wastegate flap page 23 Inspection of the fuel filter in the airframe page 25 Test run of engine page 27 Cooling system Checking the cooling system Replacing the c...

Page 108: ...em page 53 page 55 page 56 page 57 page 58 page 60 page 62 Inspecting the magnetic plug Installation of the magnetic plug page 63 page 64 Flushing the oil circuit page 65 Electric system Check of wiring Inspection and replacement of spark plugs Remove the spark plugs Installation of spark plug page 67 page 68 page 69 page 69 page 71 Propeller gearbox Checking the friction torque in free rotation C...

Page 109: ...use of compressed air to prevent leakage current WARNUNG NOTICE Do not use easily inflammable liquids or caustic clean ing agents for cleaning the engine WARNUNG NOTICE When cleaning the engine the dissolved residues of fuel oil and other environment contaminating agents are rinsed off Collect the cleaning water and dispose of it in accordance with applicable environmental reg ulations WARNUNG NOT...

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Page 111: ...ean air filter at corre spondingly shorter intervals If filter mat is damaged replace air filter WARNUNG NOTICE A dirty filter insert will not only reduce the engine per formance but might also promote premature wear of the engine WARNUNG NOTICE Never use gasoline steam caustic liquids strong de tergents particle cleaning agents or high pressure cleaners during this step WARNUNG NOTICE Do not dry ...

Page 112: ...aphic Cleaning of the filter Fig 1 08525 After cleaning NOTES Each filter pleat must be sprayed with oil After 5 to 10 min the filter will be soaked with oil noticeable by the uniform red coloring Fig 2 08526 5 2 7 5 2 7 5 2 7 A B C WARNUNG NOTICE Never use gear oil diesel or engine oil as they attract humidity 5 2 7 ...

Page 113: ...ers which are specified by the aircraft manufac turer and from ROTAX Fig 3 08527 WARNUNG NOTICE Each air filter must be secured by clamp attachment and a wire securing element See chap 05 00 00 sec tion 1 6 Filter connection must be free of oil WARNUNG NOTICE Attach new air filter free of grease at connection fac es and wire secure against loss Part Function 1 Air filter 2 Safety wire 3 Carburetor...

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Page 115: ...ck the two heat protection hoses water pump cylinder head 1 and 2 for mechanical damage Fuel and oil lines see 73 00 00 of the Heavy Maintenance Manual Fuel pumps Servo motor see 76 00 00 of the Heavy Maintenance Manual Pressure sensors Heat protection plates Wiring harness Venting hoses carburetor oil tank Cooling air duct and cooling fins of the cylinder Condensation trap NOTES Only fitted on en...

Page 116: ...Maintenance Manual Airbox fuel pressure regulator Airbox pressure sensor Airbox reversing valve Reversing valve 2x Float chamber ventilation Fig 4 00048 WARNUNG WARNING As a failure of the pressure connecting lines 1 be tween the airbox float chambers fuel regulator and pressure sensor is almost certain to cause engine stoppage they must be checked with especial care 1 1 1 1 1 1 ...

Page 117: ...ng with corrosion refer to the FAA Advisory Circular AC 43 13 See chapter AC 43 13 1B Maintenance and Repair WARNUNG NOTICE Exactly observe the tightening torques for screws and nuts Overtightening or too loose connection could cause serious engine damage Step Procedure 1 Verify the engine suspension points on the crankcase for tight fit and dam age including cracks 2 Inspect the surroundings of e...

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Page 119: ...hanical seal must be replaced inspect the quality of the coolant Fuel lines Inspect fuel lines their connections and screw fasteners Look for scuff ing marks On steel fuel lines in the area at connections fittings 2 a detailed visual inspection is necessary See Fig 5 WARNUNG NOTICE Leaking connections can lead to engine problems or engine failure Step Procedure 1 Cleaning the engine 2 Operate the ...

Page 120: ... the oil tank to the oil cooler and to the engine Also inspect the oil return line from the crankcase to the oil tank Check the pressure oil line from the oil pump to the governor flange of the gover nor and the suction oil line from the turbocharger to the oil pump espe cially in the area of the fixation screw Hose clamps kinks Check all hoses particularly in the area of the hose clamps and hose ...

Page 121: ...G WARNING Risk of electric shock Ignition OFF and system grounded Part number Description n a Compressed air approx 6 bar 87 psi n a 2 pressure gauges n a Orifice jet of 1mm 0 04 in inner diameter and 3 mm 0 12 in length or equivalent e g orifice diameter 0 040 in long 0 0250 in 60 degree approach angle according to AC43 13 latest issue n a Adapter to spark plug thread n a Connect line Step Proced...

Page 122: ... 12 20 00 page 16 January 01 2010 Graphic Checking the compression Fig 6 08529 Part Function 1 Adaptor 2 Manometer Test gauges set 3 Orifice jet 4 Compressor PP LQ PP LQ 5 17 1 5 35 6685 7 67 5 5 17 1 5 35 6685 7 67 5 2 2 6ORZ LOO 6ORZ LOO 87 21 87 21 3VL 3VL 3VL 3VL 1 4 3 A B C D 2 ...

Page 123: ...t be carried out in accordance with the BRP Powertrain instructions for contin ued airworthiness Detailed inspection of affected engine components Graphic Compression check for fault tracing Fig 7 08651 Step Procedure 1 Operate the engine until the temperatures have stabilized for a period of 5 min engine oil temperature between 50 to 70 C 122 160 F 2 Unscrew and remove top spark plugs As a genera...

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Page 125: ...ect attachment and V belt tension Belt tension To adjust the belt tension Graphic Checking the V belt tension Fig 8 00353 Step Procedure 1 Loosen the hex screw 1 M10 and the two M8 allen screw 2 and 3 2 Press the alternator upwards and tighten allen screw 3 3 Then tighten hex screw 1 M10 with tightening torque 40 Nm 30 ft lb and allen screw M8 2 with tightening torque 22 Nm 195 in lb Part Function...

Page 126: ...d04530 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 12 20 00 page 20 January 01 2010 Checking the V belt tension Inspect V belt tension as per drawing below Fig 9 00354 ...

Page 127: ... piston of cyl no 1 and no 2 are in TDC position and lock crankshaft in this position with the thread bolt 2 part no 240880 NOTES Turn crankshaft for relief the position indification until the trig ger boss 3 is between the both trigger coil 4 5 at the po sition The required recess position of the crankshaft can be addi tionally verified by looking through the crankcase recess 6 with a flash light...

Page 128: ...ectivity 914 Series Edition 2 Rev 0 12 20 00 page 22 January 01 2010 Graphic Locking the crankshaft Fig 10 08530 08531 Part Function 1 Plug screw M8x20 2 Thread bolt 3 Trigger boss 4 5 Trigger coils 6 Crankshaft 7 Hex screw M16x1 5x40 6 1 2 3 5 7 4 ...

Page 129: ...or mechanical dam age or wear 2 Check the bowden cable suspension and spring 3 Check the adjustment of the wastegate flap NOTES When the engine has been shut down the servo motor al ways runs to closed position This also applies when the TCU is switched on The servo motor moves approx 1 2 revolution and then remains in closed position In this position the wastegate flap must be completely closed I...

Page 130: ...ANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 12 20 00 page 24 January 01 2010 Graphic Fig 11 00147 Part Function 1 Wastegate actuation 2 Adjusting screw 3 Wastegate lever 4 Lubrication hole 2 1 3 4 ...

Page 131: ...nspect this fine filter 3 as described in the Aircraft Maintenance Schedule Fine filter fuel pump If the filter in the airframe is heavily soiled the two fine filters 4 inte grated in the fuel pumps must also be inspected See chap 73 00 00 Heavy Maintenance Manual WARNUNG NOTICE The fine filter is not included in delivery from BRP Pow ertrain The aircraft manufacturer is responsible for the select...

Page 132: ...rtrain Effectivity 914 Series Edition 2 Rev 0 12 20 00 page 26 January 01 2010 Graphic Inspection of the fuel filter Fig 12 00103 00157 Part Function 1 Fuel supply line 2 Fuel pumps 3 Gascolater 4 Fine filter fuel pumps AUX MAIN 3 1 2 2 4 ...

Page 133: ...ttle lever to idle position 4 Master switch ON 5 Ignition for both ignition circuits ON 6 Press starter switch for max 10 sec followed by a cooling period of 2 min 7 After engine start observe oil pressure Oil pressure has to be built up within 10 sec 8 Let engine run for approx 2 min at 2000 rpm Then first use the throttle lever to bring the engine to approx 2500 rpm and then run through warming ...

Page 134: ...k of leaks Inspect the engine for oil fuel or coolant leaks and repair as necessary WARNUNG WARNING Risk of Burns Never open the radiator cap when the cooling system is hot For safety s sake cover cap with a rag and open slowly Sudden opening of the cap could provoke the escape of boiling coolant and result in scalding WARNUNG NOTICE If the oil filter has been replaced re tighten by hand af ter th...

Page 135: ...n Effectivity 914 Series Edition 2 Rev 0 12 20 00 page 29 January 01 2010 11 Cooling system 11 1 Checking the cooling system Overview Fig 13 08579 Part Function 1 Coolant lines 2 Water pump 3 Expansion tank 4 Radiator cap with gasket 3 4 1 1 2 ...

Page 136: ...ote See Fig 14 Instruction To replace the coolant the following steps are necessary WARNUNG WARNING Risk of Burns Hot engine parts Always allow engine to cool down to ambient tempera ture before start of any work WARNUNG WARNING Risk of Burns Never open the radiator cap when the cooling system is hot For safety s sake cover cap with a rag and open slowly Sudden opening of the cap could provoke the...

Page 137: ...nt type conventional coolant waterless coolant the cooling system must be flushed See chap 12 20 00 section 11 3 6 Refill newly mixed coolant into the expansion tank highest point of the cooling system See chap 12 10 00 section 3 1 7 Fit radiator cap 8 NOTES Run the engine briefly and replenish with clean coolant as required Step Procedure Part Function 1 Attachment screw stainless steel 2 Water p...

Page 138: ...lowly Step Procedure 1 The system is flushed using pure water at a pressure of 2 bar 29 psi Where water free coolant is used the cooling system must be drained of water correspondingly after flushing The residual water must not exceed the max permissible limit prescribed by the coolant manufacturer NOTES For the flushing open the lowest located coolant hose either at water pump or radiator 2 Refil...

Page 139: ...n older engines a radiator cap with opening pressure of 0 9 bar 13 0 psi can be installed See SI 914 022 Run ning Modification latest issue Radiator cap Inspect the rubber seal 3 the pressure spring 4 and the two valves incorporated in the radiator cap for damage and leaks If necessary replace with a new original radiator cap with 1 2 bar 17 4 psi 6 open ing pressure NOTES The radiator cap must be...

Page 140: ...ertrain Effectivity 914 Series Edition 2 Rev 0 12 20 00 page 34 January 01 2010 Fig 15 08534 07620 4 Pressure spring 5 Connection to overflow bottle 6 Opening pressure of the radiator cap 7 Sealing surface 8 Tube connections Part Function ...

Page 141: ...radiator hoses hose clamps cooling air ducts General note Step Procedure 1 Inspect the bottle for damage 2 Check the venting bore 1 in the screw cap see Service Bulletin SB 914 025 Modification of the overflow bottle latest issue 3 Inspect bracket 2 for the safety wire 4 Check hose connection 3 Part Function 1 Venting bore 2 Bracket 3 Hose connection 1 2 3 WARNUNG NOTICE Equipment is to be inspect...

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Page 143: ...rottle lever lies close on the adjustment screw Instruction To synchronize when idling the following steps are necessary NOTES First the mechanical synchronization and then only the pneumatic synchronization has already been carried out Graphic Synchronization at idle speed Fig 17 05491 Step Procedure 1 Detach the resonator hose 1 see option 4 of the compensating tube 2 to separate the two air int...

Page 144: ... resistance during this procedure 3 Unscrew idle speed adjustment screw 2 until it is free of the stop 4 Insert a 0 1 mm 0 004 in feeler gauge gap X between the idle speed adjust ment screw 2 and the carburetor idle stop 3 then gently turn the idle screw clockwise until contact is made with the 0 1 mm 0 004 in feeler gauge 5 Pull out the feeler gauge and then turn each idle speed adjustment screw ...

Page 145: ...oo high the engine is harder to start Start the engine and verify the idle speed If the idle speed is too high or too low adjust accordingly with idle speed adjustment screw 2 5 Check the true running of the engine If necessary adjust with the idle mixture screw 6 See chap 12 20 00 section 12 5 Step Procedure NOTICE Part Function 1 Throttle valve lever 2 Adjustment screw 3 Idle stop position 4 Cab...

Page 146: ...nection Possible connection methods Graphic Option 1 Fig 19 08652 WARNUNG WARNING Danger of life threatening injuries caused by the pro peller rotating and stressed parts of the engine Always observe the engine from a safe place while it is running Option 1 Step Procedure 1 Remove the compensating tube 2 from the push on angular tube 4 after re moving the two clamps 3 2 Using the push on angular t...

Page 147: ...Procedure 1 Remove one end of the compensating tube 2 and tube 3 from the push on angular tube 5 after removing the two tension clamp 4 2 Using the push on angular tube 5 and compensating tube 2 install a flexible rubber hose 6 leading to the vacuum gauge 1 Part Function 1 Vacuum gauge 2 Compensating tube 3 Tube 4 Clamp 5 Angular tube 6 Rubber hose 4 6 1 2 3 5 ...

Page 148: ... 1 Remove hex screw 1 M6x6 from intake manifold 2 and connect the vacuum gauge 2 Remove the compensating tube 3 with attached tubes 4 connection be tween intake manifolds and plug the fittings in the intake manifolds 3 After synchronization tighten the screw M6x6 1 with LOCTITE 221 Part Function 1 Hex screw M6x6 2 Intake manifold 3 Compensating tube 4 Tube 2 1 2 1 3 4 ...

Page 149: ...acuum gauge 2 Clamp the tube 2 with hose clamping pliers 1 Observe the position The compensation tube 3 does not have to be removed 3 Unscrew the screw 4 4 Install the hose nipple M6 5 with the sealing ring 6 5 After synchronization tighten the screw M6x6 4 with LOCTITE 221 Part Function 1 Clamping pliers 2 Tube 3 Compensation tube 4 Screw M6x6 5 Hose nipple 6 Sealing ring 1 2 3 5 4 6 ...

Page 150: ...achieved inspect the idle jets for contamina tion and clean if necessary WARNUNG WARNING Risk of life threatening injuries caused by propeller Secure the propeller region before test run watch it Secure a safe area around propeller during test run Setting of more than 1 2 turn If a setting of more than 1 2 turn is required repeat mechanical synchronization to pre vent too high a load on the idle s...

Page 151: ... on both carburetors retard the throttle and observe the pressure gauge settings The pressure gauges should show the same reading for both carburetors NOTES Discrepancies must be compensated for by adjusting the off idle adjustment 1 3 Final idle speed adjustment may be required by resetting the idle speed adjust ment screws 2 4 Equal adjustment must be made on both carburetors 5 Any major adjustm...

Page 152: ... removal Any minor differences in balance at idle speed will be compen sated for Refit the screw plug M3 5 3 and hex screws M6x6 with gasket pos 1 Fig 21 Graphic Inspect operating range idle speed Fig 23 08682 WARNUNG NOTICE Follow the instructions of the instrument manufacturer Part Function 1 Idle adjustment 2 Idle speed adjustment screw 3 Screw plug M3 5x5 4 Idle mixture screw 3 2 1 4 ...

Page 153: ...rocedure 1 Remove drip tray 1 2 Open attachment screw 2 3 Remove float chamber 3 with gasket 4 and both floats 4 Remove both floats 5 from the float chamber 5 Inspect the float chamber for contamination and corrosion WARNUNG NOTICE If any contamination on float chamber the find out what the cause is and take corresponding action to rectify the problem Inspect and clean the complete fuel sys tem in...

Page 154: ...NCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 12 20 00 page 48 January 01 2010 Graphic Float chamber Fig 24 08681 Part Function 1 Drip tray 2 Attachment screw 3 Float chamber 4 Gasket 5 Float 5 4 3 2 1 ...

Page 155: ...n of the idle jet or additional pneu matic synchronization will be necessary See chap 12 20 00 section 12 3 Step Procedure 1 Close idle mixture screw 4 by turning clockwise to screw in fully and then opening again by 1 5 turns counter clockwise 2 Starting from this basic adjustment the idle mixture screw 4 is turned until the highest idle speed is reached 3 The optimum setting is the middle betwee...

Page 156: ... of life threatening injuries caused by propeller Adjust bowden cables so that the throttle valve and the choke actuation of the starting carburetor can be fully opened and closed Bowden cables and lever must not jam WARNUNG WARNING Risk of life threatening injuries caused by propeller With carburetor actuation not connected the throttle valve is fully open The initial position of the CD carbu ret...

Page 157: ...rain Effectivity 914 Series Edition 2 Rev 0 12 20 00 page 51 January 01 2010 Graphic Checking the carburetor actuation Fig 25 02480 Part Function 1 Connection for throttle valve 2 Connection for choke actuation 3 Return springs 1 mm 1 2 3 3 ...

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Page 159: ...ctivity 914 Series Edition 2 Rev 0 12 20 00 page 53 January 01 2010 13 Lubrication 13 1 General Overview Fig 26 08238 08580 Part Function 1 Oil tank 2 Drain screw M12x12 3 Oil cooler optional 4 Oil filter IN O U T to oil pump back from engine 1 3 4 2 ...

Page 160: ... entering the oil system Replacement of the oil filter and the oil change should be effected quickly and without interruption to prevent a draining of the oil system and the hydraulic tappets Oil lines Oil connections Oil lines and other oil connections are not normally removed WARNUNG WARNING Risk of Burns Hot engine parts Always allow engine to cool down to ambient tempera ture before start of a...

Page 161: ...d safety wire Tightening torque 25 Nm 18 5 ft lb NOTES When installing the oil drain screw one has to lock the nut which is on the floor of the oil tank This will prevent damage of the oil tank floor WARNUNG NOTICE Only use brand name oil in accordance with the latest Operators Manual and SI 914 019 Selection of suit able operating fluids latest issue WARNUNG NOTICE The engine must not be cranked ...

Page 162: ...l tool Fig 27 02734 Procedure Unscrew the oil filter WARNUNG WARNING Risk of Burns Hot engine parts Always allow engine to cool down to ambient tempera ture before start of any work WARNUNG NOTICE To ensure correct functioning of the oil circuit and the forced flow lubrication use genuine ROTAX oil filter only Only these filters will ensure correct pressure in the by pass valve part number Descrip...

Page 163: ...Install oil filter Fig 28 08550 WARNUNG NOTICE After test run inspect tight fit of oil filter Step Procedure 1 Clean the contact surface 1 of the oil pump housing 2 with a clean cloth 2 Apply thin film engine oil on the gasket 3 of the oil filter 4 3 Install the oil filter on the engine 4 Screw on oil filter until oil filter gasket is seated solidly 5 Tighten oil filter with a 3 4 turn 270 Part Fu...

Page 164: ... abrasion repair or overhaul the engine in accordance with the BRP Powertrain instructions for continued airwor thiness If the filter mat is clogged by foreign matter the lube oil reaches the bearing points unfiltered via the by pass valve in the oil filter Unclear findings In the case of unclear findings WARNUNG NOTICE The filter insert must be inspected carefully for metal chips Step Procedure 1...

Page 165: ... Fig 29 08427 00181 WARNUNG NOTICE If the oil circuit is contaminated replace the oil cooler and flush the oil circuit See chap 12 20 00 section 15 Proper judgement requires years of experience in repair of piston engines Part Function 1 Filter housing 2 Filter cover 3 Gasket ring 4 Filter element 5 Filter mat from oil pump 5 4 3 2 1 5 to bearings ...

Page 166: ...rocedure to clean the oil tank Step Procedure 1 Detach the profile clamp 2 and remove the oil tank cover 3 together with the O ring 4 and the oil lines 2 Remove the inner parts of the oil tank such as the baffle insert 5 and the par tition 6 3 Clean oil tank 8 and inner parts 5 6 and check for damage WARNUNG NOTICE Incorrect assembly of the oil tank components can cause engine faults or engine dam...

Page 167: ...ctivity 914 Series Edition 2 Rev 0 12 20 00 page 61 January 01 2010 Graphic Cleaning the oil tank Fig 30 05556 Part Function 1 Drain screw 2 Profile clamp 3 Oil tank cover 4 O ring 5 Baffle insert 6 Partition 7 Gasket ring 8 Oil tank 7 2 5 3 6 4 8 1 ...

Page 168: ...re each first start up after reinstallation e g after overhaul after maintenance work during which the lubrication system was opened and voided WARNUNG NOTICE Purging of the oil system is extremely important for op eration and service life of the engine and therefore the procedure must be followed meticulously It must be carried out in accordance with SI 914 020 Purging the lubrication system late...

Page 169: ...hips in low numbers as depicted in Fig 31 can be tolerated if the accumulation is below 3 mm 0 125 in Steel chips in larger numbers If there are larger accumulations of metal chips on the magnetic plug the engine must be repaired or overhauled in accordance with the BRP Pow ertrain instructions for continued airworthiness Unclear findings In the case of unclear findings Contamination Trace the cau...

Page 170: ... 08565 08566 08564 08563 14 1 Installation of the magnetic plug Install The following steps are necessary Inspect all systems for correct function Detailed inspection of affected engine components acceptable not acceptable magnetic plug Step Procedure 1 Clean the magnetic plug 2 Refit the magnetic plug Tightening torque 25 Nm 18 5 ft lb 3 Safety wire the plug ...

Page 171: ... battery Purging of the oil system see chap 12 20 00 section 13 7 Equipment WARNUNG WARNING Risk of electric shock Switch off ignition and remove key Disconnect nega tive terminal of aircraft battery WARNUNG NOTICE The oil level in the tank must not drop below the end of suction pipe otherwise air will be sucked in again Step Procedure 1 Turn engine by hand in direction of engine rotation to retur...

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Page 173: ...ies Edition 2 Rev 0 12 20 00 page 67 January 01 2010 16 Electric system Overview Fig 32 08552 08553 Part Function 1 Spark plug connectors 2 Dual ignition coil 3 Ignition cable 4 Electronic module 5 Plug connectors 6 Grounding cable 7 Protection hose 1 3 2 4 5 6 6 7 ...

Page 174: ...pect plug connections between electronic module and ignition coils for cor rosion or damage and replace if necessary 5 Verify plug connections of alternator cables with rectifier regulator and connec tions of all cables on rectifier regulator for good contact tight fit corrosion or damage and replace if necessary 6 Inspect grounding cables for tight fit corrosion or damage and replace if nec essar...

Page 175: ...g AVGAS 100LL can re sult in increased wear of the spark plugs Reduce renewal intervals accordingly Special tool Ensure that the following spark plugs corresponding to engine type are employed and that the correct spark plug socket is used 16 2 1 Remove the spark plugs Remove Remove the spark plugs and store them according to cylinder and posi tion Always replace both spark plugs of a cylinder and...

Page 176: ...e Spark plug face reveals the following about the operating condition of the engine Electrode gap New Wear limit 0 6 0 7 mm 0 023 0 027 in 0 9 mm 0 035 in Spark plug face Information light coloured to brown plug and calibration of the engine are correct velvet black Indicates the following mixture too rich insufficient air intake clogged air filter engine operating temperature too low oily glossy ...

Page 177: ... and tighten spark plug to 20 Nm 177 in lb on the cold engine Graphic spark plugs Fig 33 00086 WARNUNG WARNING Eyes and skin irritation Rinse off with water in the case of contact with eyes or skin May be harmful if swallowed WARNUNG NOTICE Always replace both spark plugs of a cylinder and do not interchange spark plugs between cylinders WARNUNG NOTICE Heat conduction compound at the ground electr...

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Page 179: ... propeller can be turned by hand 15 or 30 de grees depending on the profile of the dog gears installed This is the maximum amount of movement allowed by the dog gears in the tor sional shock absorption unit 3 Turn the propeller by hand back and forth between ramps taking into consid eration the friction torque No odd noises or irregular resistance must be no ticeable during this moment 4 Attach a ...

Page 180: ...4530 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 914 Series Edition 2 Rev 0 12 20 00 page 74 January 01 2010 Graphic Checking the friction torque Fig 34 05694 UDIW LQ 1 IRUFH LQ 1 lQJH P OHQJWK LQ P ...

Page 181: ... note The gearbox must be inspected repaired or overhauled in accordance with the BRP Powertrain instructions for continued airworthiness Detailed inspection of the affected gearbox components in accordance chap 72 00 00 in the Heavy Maintenance Manual Crack testing of the propeller shaft is not normally planned but can be carried out if cracks are suspected ...

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Page 183: ......

Page 184: ...Engine serial no Flugzeugtype Type of aircraft Flugzeugkennzeichen Aircraft registration no ROTAX Vertriebspartner ROTAX authorized distributor and TM are trademarks of BRP Powertrain GmbH Co KG 2010 BRP Powertrain GmbH Co KG All rights reserved ...

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